You want to stay ahead of the curve in Lean Manufacturing. What’s the one trend you can’t ignore?

In Lean Manufacturing, by Embracing below trends, companies can enhance efficiency, productivity, and competitiveness. Industry 4.0 Integration: Incorporate technologies like IoT, AI, and robotics into Lean Manufacturing practices. IoT Sensors: Utilize real-time data collection for better monitoring and optimization. AI and Predictive Analytics: Analyze data to predict equipment failures and optimize production schedules. Robotics and Automation: Improve efficiency by automating repetitive tasks and using collaborative robots. Digital Twins: Simulate manufacturing systems to test process improvements and optimize production. Cloud-Based Solutions: Access data and applications remotely for real-time collaboration and decision-making.

The trend you can't ignore in lean manufacturing is the rise of digitalization and Industry 4.0 technologies. Incorporating technologies such as the Internet of Things, AI, machine learning, and big data analytics can significantly enhance efficiency, productivity, and waste reduction. These technologies provide real-time data and predictive analytics, allowing for quicker, more informed decisions, proactive problem-solving, and increased overall operational efficiency. Embracing this digital transformation is essential for staying ahead of the curve in lean manufacturing.

We all know what digital transformation is, but what am surprised with our company is when it invested a lot in IOT sensors that collects data in all key parameters of our machines, it really helped a lot after all the sweat in installation and when we found plenty of room in improving machines leading to reducing waste and detecting trouble and optimizing process.

Digital transformation is an interesting field, which will have a great impact on all business functions, especially on production and logistics. But if we look at digital transformation from the side, we see, that it is just an upgrade of current processes with digital solutions. Of course, we have IOT, AI, digital twin etc., but for the work to get done we have to follow business processes. So if you are thinking about digital transformation, you must also think about business processes, because they are foundations on which your digital transformation will be done. So your job is to focus on your business processes first in a LEAN way. Starting digital transformation without lean processes is a mistake.

What I learned so far: Invest heavily on data collection from machines using IOT sensors (tact time, machine current, chamber temperature, pressure, humidity, and any related important paramaters) Then simplify dashboard for analysis of trends, set triggers and alarms and threshold for each parameter. Set a simple traffic light of Go, No-go. And analyze and improve parameters and machine condition leading to leaner manufacturing process. It's a big relief when everything looks fine just looking at the dashboard and everything is a Go and Green.

What I experienced so far when a company is moving into digital transformation, it is necessary to be smart in choosing platform that will be used in IoT sensors, software tools, network connectivity, cloud server, and other computing architecture. - Choose a company that will provide this in one simple package. - Enough features that have room for future technological expansion - Fast installation that can be completed within a month - Parts and instruments that are not too tiny and easily break. Quality product. - Set, install, and forget system that does not need repetitive maintenance. - Computing system that has interconnectivity to other platforms - Simple solution and focused only on needed key parameters monitoring. Simplify.

The most important risk is software provider. There are many software providers, who promises everything, just to sell you their software. Companies usually don't do a user specification and if they prepare it, it is so general, that it is useless. At the end, companies pays with extra money for these mistakes. If you are heading down the road to complete digital transformation, I'm putting this on your heart: Use an Independent management consultant, which will grab your hand and leads you to the finish line. Make sure that they are responsible for results and that they are competent - check references. They will act as independent "gatekeeper", making sure that yours interests are followed.

To stay ahead in manufacturing, we must build on Industry 4.0 principles and advance further. This entails enhancing collaboration between humans and machines using technologies like robotics, augmented reality (AR), and virtual reality (VR) to improve decision-making. Adopting artificial intelligence (AI) and machine learning (ML) is crucial for creating self-optimizing manufacturing systems, leading to smart factories that adjust production, predict maintenance, and optimize resources in real time. We need to also prioritize environmental sustainability involves green manufacturing practices such as renewable energy, waste reduction, circular economy principles, and eco-friendly processes thus aligning with global sustainability goals.